info@exclusivehydraulics.co.za🔧 Hydraulic systems play a critical role in the smooth operation of industries such as construction, mining, agriculture, and manufacturing. These systems generate massive amounts of power using pressurised fluid to perform heavy-duty tasks. But what happens when a hydraulic system starts to fail?
In many cases, hydraulic system failure does not happen overnight. There are often clear signs that, if recognised early, can help you avoid costly downtime, prevent equipment damage, and maintain workplace safety.
The Most Common Warning Signs Of Hydraulic System Failure
…and how to respond effectively.
1. Unusual Noises: Whining, Knocking Or Banging
If your hydraulic machinery begins to sound different – pay attention. Any change in noise usually signals a problem or hydraulic system failure.
- A whining or high-pitched sound often points to aeration (air entering the system), which can reduce efficiency and cause internal damage.
- Knocking or banging may indicate cavitation, where vapour bubbles implode under pressure, damaging internal surfaces and components.
Both aeration and cavitation can destroy pumps and reduce the lifespan of other hydraulic parts. According to Miller-Bradford & Risberg, these noises are among the first signs of trouble.
👉 What to do: Inspect for leaks or cracked fittings where air could be entering. Replace any damaged seals or hoses and ensure fluid levels are topped up.
2. Overheating Hydraulic Fluid
Hydraulic oil has an optimal working temperature. When fluid runs too hot, it can degrade rapidly, reducing lubricity and accelerating wear across your system.
Overheating may be due to:
- Clogged filters.
- Excessive system pressure.
- Failing cooling systems.
According to Servo Kinetics, operating above 82°C (180°F) reduces hydraulic fluid lifespan and efficiency significantly.
👉 What to do: Monitor fluid temperatures with sensors. Ensure your cooling system is functioning properly and clean filters regularly to prevent flow restrictions and hydraulic system failure.
3. Sluggish Or Inconsistent Operation
If your hydraulic system is operating slower than usual, hesitating, or acting unpredictably, this may indicate:
- Internal leakage within cylinders or pumps.
- Dirty or degraded hydraulic fluid.
- Blocked filters or valves.
- Air trapped in the system.
These symptoms usually develop gradually and are often overlooked – until machinery collapses altogether and you experience a hydraulic system failure.
👉 What to do: Schedule a full system flush if fluid contamination is found. Check actuators for wear, and replace blocked or old filters.
4. Fluid Leaks Around Seals, Hoses Or Valves
Visible leaks are one of the most obvious – and urgent – red flags. Hydraulic systems rely on maintaining pressure, and any leak reduces performance while increasing the risk of complete system failure.
According to DNC Hydraulics, fluid leaks can cause:
- Slip hazards for workers.
- Contaminated environments.
- Pressure loss and overheating.
👉 What to do: Inspect hoses, gaskets, and valve bodies regularly. Replace damaged seals, tighten loose connections, and never ignore a visible leak.
5. Jerky Or Erratic Movements
Hydraulic systems are designed for smooth, continuous motion. If your machine suddenly jerks or hesitates, it might be due to:
- Air bubbles disrupting flow.
- Dirty or thickened hydraulic oil.
- Cylinder seal wear or failure.
👉 What to do: Bleed the system to remove air, and test actuator cylinders for damage. Replace fluid if it appears dark or thick.
6. Overheating Of Components
Aside from fluid temperature, excessive heat around components such as motors, pumps, or valves is a strong indication that your system is under stress and may result in hydraulic system failure.
Causes include:
- Constant pressure build-up.
- Malfunctioning heat exchangers.
- Inadequate lubrication.
Overheated components can warp or seize, leading to immediate failure and costly repairs.
👉 What to do: Use thermal imaging or heat sensors to identify hotspots. Investigate the root cause – whether it is pressure imbalance, poor fluid quality, or system overload.
7. Low Or Fluctuating System Pressure
When pressure drops unexpectedly or fluctuates, efficiency drops and safety becomes compromised. You may notice reduced lifting capacity, weak movements, or sluggish responses.
According to Sapphire Hydraulics, pressure issues may be caused by:
- Internal leaks.
- Worn pump components.
- Pressure relief valve failures.
👉 What to do: Check pressure readings against manufacturer specifications. Test valves and pumps for wear and inspect for any internal leakage or component failure.
Preventing Hydraulic System Failure: Smart Strategies
Now that you are familiar with the early warning signs, how can you actively avoid hydraulic failure?
✅ 1. Follow A Preventative Maintenance Schedule
Routine maintenance should include:
- Fluid checks.
- Filter replacements.
- Component inspections.
- Pressure testing.
It is far more cost-effective to fix minor issues during scheduled maintenance than to react to unexpected breakdowns and a complete hydraulic system failure.
✅ 2. Use High-Quality Fluids And Filters
Using inferior hydraulic oil or generic filters can accelerate wear. Stick with manufacturer-approved brands and ensure filters meet the required micron rating.
✅ 3. Educate Your Operators
Well-trained operators are your first line of defence. Encourage them to report any abnormal behaviour early – before damage worsens.
✅ 4. Keep Records Of Issues And Interventions
Log every system irregularity and maintenance action. This helps identify recurring problems and improve diagnostics.
✅ 5. Work With Trusted Experts
Partnering with a professional hydraulic service company like Exclusive Hydraulics and Engineering means you have access to advanced diagnostics, quality parts, and expert repairs – minimising the risk of unplanned downtime.
Why Early Detection Saves Money And Time
A Hydraulic system failure does not just mean downtime – it often leads to chain reactions across your business:
- Productivity stalls.
- Deadlines slip.
- Safety risks increase.
- Repair costs skyrocket.
By identifying warning signs early and taking corrective action, you can dramatically extend the lifespan of your hydraulic machinery and protect your bottom line.
Trust The Experts At Exclusive Hydraulics
At Exclusive Hydraulics and Engineering, we specialise in:
- Hydraulic system repairs and overhauls to avoid hydraulic system failure.
- Preventative maintenance plans.
- High-performance parts and fittings.
- Custom cylinder rebuilds.
Whether you operate a fleet of earthmovers or precision industrial equipment, our team is here to support you every step of the way.
🔧 Contact us now to schedule a professional inspection or discuss a tailored maintenance plan.
Related Reads You Will Love:
📘 7 Amazing Hacks That Actually Reduce Hydraulic Systems Downtime.
📘 Why Is My Hydraulic Pump Failing? 5 Annoying Causes You Should Know Now.
Final Thought
Hydraulic systems are tough, but not invincible. If you learn to listen to your machines – literally and figuratively – you will catch the warning signs before breakdowns occur.
Do not wait for a costly hydraulic system failure. Stay proactive, stay efficient, and stay safe.
🛠️ Need help diagnosing or preventing issues? Call the Exclusive Hydraulics team today or request a quote online.
